Installation Reference, Volvo Penta IPS 3, Propulsion Unit and Engine - Using Lifting Hood or Fork lift special toolInstallation reference , Volvo Penta IPS3 Propul-sion Unit and Engine foundation Revision: Document N°: 47701029Release date: 04-2010

Installation kitNOTE! Read the “Installation Manual Volvo Penta IPS” before the installation work of IPS propulsion unit and engine is started.Other electrical installations, please refer to

actual “Installation Manual EVC, Volvo Penta IPS.”

WARNING! Make sure all safety precautions are made prior to lifting to avoid personal injuries and damage on equipment.

NOTE! Before installing propulsion unit and engine, make sure that the rest of the installation work in the engine compartment has been completed. In addition, all cables and hoses must be correctly located and clamped.

C*

E F G

B*A D

* not included in the kit

IMPORTANT!Check that engine chassis no. and propulsion unit chassis no. are identical.

Chassis no. identification

Chassis no.

Engine chassis no.

Chassis no.

NOTE!The Chassis no must match both drivlines.

IMPORTANT!Grease the bolts before attaching.

Put the clamp ring in placeWipe rubber sealing ring and apply rubber lubricant, Volvo Penta part no. 3817243. Do this as late as possible before mounting the propulsion unit.Put the clamp ring in place in the hull.

IMPORTANT!Do not use vaseline or grease on o-ring.

Select dead-rise angle on the special tool matching the hull.

Attach the lifting hood using six bolts, tightening using hand power.

Mount the lifting hood on the IPS unit

Wipe rubber sealing ring and apply rubber lubricant, Volvo Penta part no. 3817243. Do this as late as possible before mounting the propulsion unit.Put the clamp ring in place in the hull.

IMPORTANT!Do not use vaseline or grease on o-ring.

4a

Tilt and mount the propulsion unit Tilt and locate the propulsion unit under the hull

Put the propulsion unit on the special tool. Remove the Clamp ring and rub-ber sealing ring from the propulsion unit.Apply rubber lubricant on sealing ring, Volvo Penta part no. 3817243.

Using the Fork lift special tool

h min: 1100 mm

1 2 3

4 5

Installing the engine

WARNING! Always use three lifting eyes when lifting the engine.

NOTE! Unequal loading can cause engine vibrations.

Check:Equal loading on mounts. Check on three points using setting tool 21244540.

3

4b 5 6 7

1

300 Nm (220 lbf.ft)

Installing the sea water inlet

Seawater filterNecessary clearance above filter (for disassembly): 120 mm (5”)

Seawater intakeInstall intake in front of engine, close to keel line.

Check: Drive shaft flange-to-flange dis-tance. Adjust engine if needed.If drive shaft have been disassem-bled us marking for proper assebly. Male end against engineAligning of arrows.

Connecting the drive shaft Connecting the oil cooler

Tightening torque: 70–80 Nm (52–60 lbf.ft)

Jackshaft lengthL-install700–800 mm1100–1200 mm1500–1600 mm1900–2000 mm2400–2500 mm

Tightening torque: 80 Nm (37 lbf.ft)

370±15 mm (15”±0.6)

IPS sideEngine side

Tightening torque: 70–80 Nm (52–60 lbf.ft)

Wipe surfaces

O-ring, use grese to keep in place.

Tightening torque: 48–52 Nm (35–38 lbf.ft)

Tightening torque: 15–20 Nm (11–15 lbf.ft)

Connect the electrical connectionsConnect the fuel

Installing the exhaust line Connecting the fuel pipes and elelctrical connections

BA C

NOTE!Place O-ring in ex-haust bend

Mount the protective anode

IMPORTANT! - Do not bond the IPS units together.- Do not bond the IPS to the engine or any other component on board the boat.- Do not bond any other equipment to the IPS external anode.- Anode must be isolated from conducting hull material.

IMPORTANT!Apply corrosion protection, part no. 9510227, on bonding connections.Use marine sealant on the through hull fittings.

Protective anode

8 9 10 11

12a 13a

NOTE! Min. distance between exhaust bend and transom: 50 mm (2”).

IMPORTANT!Make sure the exhaust hose has no bends. Refer to figure. If exhaust riser is used, the exhaust hose needs to be shortened.

Connect cables to IPS unit and SUS

Oil temp. and pressure

EVC bus cable

SECONDARY (S)

PRIMARY (P)

NOTE! When using jack shaft the exhaust hose might need support not to bend.

REV. PICKUP

Tightening torque: 70–80 Nm (52–60 lbf.ft)

CalibrationCalibrate the propulsion unit positions by using the parallel alignment tool, special tool and the VODIA tool in combination with the switch box. Please refer to Installation Manual Volvo Penta IPS and VODIA User’s Guide.

12bCalibrationCalibrate the propulsion unit positions by using the Laser alignment tool

Inlet hose dimension: 63 mm (2.5”)

Lifting force: Max. 20000 N (4400 lbf)16 x M14 bolts, placed as in figure.Tighten all bolts, 3 turns.

Raise the propulsion unit and attach the bolts

Final torque:110–120 Nm(81–89 lbf.ft)

2

13b

A B